Job Overview

Performs maintenance management by supervising the maintenance team, establishes priorities in maintenance schedules, and ensures Safety, Health & 5S of all the equipment and working Environment.

Job Requirements

• Responsible for overall maintenance activities of injection molding machines and auxiliary equipment including chillers, cooling towers, dryers, compressors, material loaders, granulators, hot runners, and temperature controllers.
• Ensure maximum machine availability and minimum unplanned downtime.
• Lead troubleshooting activities related to electrical, electronic, hydraulic, pneumatic, mechanical, PLC, HMI, VFD/servo drives, and control systems.
• Ensure proper functioning of machine safety interlocks, emergency stops, guards, and other safety systems.
• Develop and implement machine guarding programs as per applicable standards.
• Develop, implement, and monitor preventive and predictive maintenance schedules.
• Plan and execute daily, weekly, monthly, and annual maintenance activities.
• Maintain accurate equipment history, maintenance records, and documentation.
• Monitor key maintenance KPIs including Machine Availability, MTBF, MTTR, PM Compliance, Maintenance Cost, and Spare Consumption.
• Lead the maintenance team during critical machine breakdowns and ensure timely restoration of equipment.
• Conduct Root Cause Analysis (RCA) for major and repetitive equipment failures and implement corrective actions.
• Identify opportunities for reduction in electricity consumption, energy cost, and CO2 emissions.
• Lead, manage, train, and develop the maintenance team to improve technical capability and performance.
• Control maintenance expenses without compromising equipment reliability, quality, or safety.
• Identify critical spare parts and maintain appropriate minimum and maximum stock levels.
• Coordinate with Purchase and suppliers for timely procurement of critical spares.
• Track spare-part consumption and replacement history.
• Ensure compliance with all company safety procedures during maintenance activities.
• Ensure strict adherence to Lockout/Tagout (LOTO) procedures.
• Conduct periodic inspections of machine safety systems and support safety and statutory audits.
• Ensure technicians follow standard maintenance procedures and safe working practices.
• Drive TPM, 5S, Kaizen, preventive and predictive maintenance practices.
• Support new machine installation, commissioning, relocation, and machine modification projects.
• Participate in CAPEX projects and technical evaluation of new equipment.
• Coordinate with machine manufacturers, OEMs, and external service providers for specialized technical support.
• Ensure adherence to applicable quality, environmental, and safety management systems.

Education and Knowledge

• BE / B.Tech in Mechanical or Electrical Engineering.
• Strong knowledge of injection molding machines and associated auxiliary equipment.
• Good knowledge of hydraulic and pneumatic systems.
• Good understanding of electrical control panels and industrial electrical systems.
• Knowledge of PLCs, HMIs, VFDs, servo drives, sensors, and industrial automation.
• Knowledge of heaters, thermocouples, temperature controllers, and hot-runner systems.
• Good understanding of compressors, chillers, cooling towers, dryers, and other molding auxiliaries.
• Strong troubleshooting and Root Cause Analysis skills.
• Knowledge of preventive and predictive maintenance systems.
• Good knowledge of TPM, 5S, Kaizen, and maintenance KPI management.
• Knowledge of CMMS / maintenance management software and maintenance documentation.
• Knowledge of IATF 16949, ISO 14001, and ISO 45001 requirements.

Critical Experience

• More than 6 years of experience in maintenance within the Automotive / Plastic Injection Molding manufacturing industry.
• Strong hands-on experience in maintenance of injection molding machines and auxiliary equipment.
• Experience in electrical, mechanical, hydraulic, pneumatic, and automation troubleshooting.
• Experience in PLC, HMI, VFD/servo drive, sensors, and machine control systems.
• Experience in preventive and predictive maintenance planning and execution.
• Experience in handling critical machine breakdowns, RCA, and corrective action implementation.
• Experience in leading and developing a maintenance team.
• Experience in TPM, 5S, Kaizen, and maintenance KPI improvement.
• Experience in critical spare management and maintenance cost control.
• Experience in new machine installation, commissioning, relocation, and modification projects.
• Automotive connector manufacturing experience would be an advantage.

Competencies